Structural polymer core assembly, method of manufacture and method of use
3 Assignments
0 Petitions
Accused Products
Abstract
A composite structure, and method of manufacturing it, having a specified width, length, and height defining a top and bottom the composite structure. The composite structure includes a three dimensional structural core constructed of a polymer with a first series of a geometric pattern repeated along its length. The structural core also has a second series of the geometric pattern repeated along the width thereof. The geometric patter may be a sinusoidal curve or a substantially pyramidal shape. The composite structure also includes a first reinforcement layer made of a polymer positioned above the structural core and bonded thereto. It also includes a second reinforcement layer made of a polymer that is positioned below the structural core and bonded thereto. The composite structure may also include a decorative layer above the first reinforcement layer, an acoustical batting layer positioned between the first reinforcement layer and the structural core, and may include fire retardant chemicals.
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Citations
52 Claims
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1-17. -17. (canceled)
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18. A method of utilizing a thermoformable composite structure having a specified width, length, and height defining a top and bottom of said composite structure comprising:
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providing a single thermoformable three dimensional structural core constructed of a fiber infused thermoplastic with a pyramidal geometric pattern repeated along the length thereof, said pyramidal geometric pattern repeated along the width thereof; forming said pyramidal geometric pattern so that it is symmetric about a neutral axis of said structural core and is comprised of a plurality of pyramidal shapes; forming each of said pyramidal shapes to have four side faces which intersect to form edges; forming each of said edges to include a radius; forming said pyramidal geometric pattern to have a series of peaks and troughs that have flat bottoms and tops; thermally bonding a thermoformable first reinforcement layer to the top of said structural core wherein said first reinforcement layer is constructed of the same fiber infused thermoplastic as said structural core; and thermally bonding a thermoformable second reinforcement layer to the bottom of said structural core wherein said second reinforcement layer is constructed of the same fiber infused thermoplastic as said structural core. - View Dependent Claims (20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30)
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19. (canceled)
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31-42. -42. (canceled)
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43. A method of manufacturing a structural composite for use in the interior of a vehicle comprising:
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providing a sheet of a fiber infused thermoplastic; preheating said sheet of fiber infused thermoplastic; forming said sheet into a single thermoformable structural core with a pyramidal geometric pattern repeated along the length thereof and said pyramidal geometric pattern repeated along the width thereof by way of compression; forming said pyramidal geometric pattern so that it is symmetric about a neutral axis of said structural core and is comprised of a plurality of pyramidal shapes; forming each of said pyramidal shapes to have four side faces which intersect to form edges; forming each of said edges to include a radius; forming said pyramidal geometric pattern to have a series of peaks and troughs that have flat bottoms and tops; laminating a thermoformable first reinforcement layer constructed of the same fiber infused thermoplastic as said structural core onto the top of said structural core; laminating a thermoformable second reinforcement layer constructed of the same fiber infused thermoplastic as said structural core onto the bottom of said structural core; affixing a decorative layer to the outer portion of said first reinforcement layer; and forming said structural composite into the shape for which it will be used in said interior of said vehicle. - View Dependent Claims (44, 45)
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46. (canceled)
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47. A method of continuously manufacturing a structural composite comprising:
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providing a sheet of polymer; preheating said sheet of polymer; providing a forming apparatus comprised of two opposing portions; each opposing portion having raised areas which intermesh when said two opposing portions are brought together; continuously feeding said preheated sheet of polymer into said forming apparatus and forming said sheet into a structural core with a geometric pattern repeated along the length and width thereof; laminating a first reinforcement layer constructed of a polymer onto the top of said structural core; laminating a second reinforcement layer constructed of a polymer onto the bottom of said structural core. - View Dependent Claims (48, 49, 50, 51)
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52. A method of continuously manufacturing a structural composite comprising:
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providing a sheet of polymer; preheating said sheet of polymer; providing a forming apparatus comprised of an array of raised areas situated on a single, one-sided stationary or moving surface; continuously feeding said preheated sheet of polymer onto said forming apparatus and forming said sheet into a structural core with a geometric pattern repeated along the length and width thereof by way of vacuum or other assisted molding; laminating a first reinforcement layer constructed of a polymer onto the top of said structural core; laminating a second reinforcement layer constructed of a polymer onto the bottom of said structural core.
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Specification